Battery

ABSTRACT

A battery, for example, a rechargeable battery (e.g. lithium ion battery) having a casing with battery terminals. The casing, for example, includes an upper section, middle section, and lower section connected together. The battery can be connected to one or more battery trays having the same height or different heights for various applications.

FIELD

The present invention is directed to a battery, for example, arechargeable battery such as a rechargeable lithium ion battery for usein a vehicle such as a motorcycle, road bike, dirt bike, trike, scooter.Moped, automobile, truck, plane, boat, jet ski, recreation vehicle (RV),all-terrain vehicle (ATV), four wheeler, and other applications (e.g.electrical back-up unit).

BACKGROUND

Typically, most vehicle batteries in use today are lead acid batteries.However, more recently, lithium ion batteries or other rechargeablebattery chemistries are being developed for use in vehicles and otherapplications.

There exists a need for improved batteries.

SUMMARY

The rechargeable battery according to the present invention, forexample, is a rechargeable lithium ion battery for use in a vehicle. Therechargeable battery according to the present can also be used withother battery chemistries.

The rechargeable battery comprises a casing having a positive terminal,a negative terminal, and one or more internal cells contained within thebattery casing. For example, the rechargeable battery comprises multiplecells (e.g. six cells) connected together in series providing orconnected to a positive terminal and negative terminal. For example, theindividual battery cells each have a positive tab and negative tab sothat the positive tab of one cell can be connected (e.g. soldered,fastened, or otherwise connected) to the negative tab of the next cellto provide a series arrangement between the cells.

The battery casing, for example, can comprise an upper section, middlesection, and lower section connected or assembled together. For example,the battery cells can be installed within the battery casing prior toassembly. Further, for example, the upper section, middle section, andlower section can be structured and arranged to connect together (e.g.configured to snap fit together).

The upper section of the battery casing, for example, can be fitted witha positive terminal and a negative terminal made of electricallyconductive material (e.g. lead or lead composite metal material). Forexample, an insert molded type positive terminal and an insert moldedtype negative terminal is molded into the battery casing. For example,the insert molded type positive terminal and insert molded type negativeterminal are molded in spaced apart upper wall portions of the casing.

The casing, for example, is molded (e.g. injection molded, vacuummolded) plastic material (e.g. polyethylene terephthalate,polypropylene). For example, the casing is made of a single layer ofmaterial or multiple layers of material (e.g. multiple layers ofdifferent plastic materials). Further, the insert molded type positiveterminal and insert molded type negative terminal can be insertinjection molding to the wall of the battery casing during injectionmolding of the battery casing.

The insert molded type positive terminal and insert molded type negativeterminal can be structured and arranged to connect, respectively,directly to a positive battery cable and a negative battery cable. Forexample, the insert molded type positive terminal and insert molded typenegative terminal can be provided with one or more threaded holes sothat a connecting bolt can connect each battery cable to each insertmolded type terminal. Alternatively, or in addition, the insert moldedtype positive terminal and insert molded type negative terminal are eachprovided with a protrusion or ear having a through hole to allow a boltand nut to connect each battery cable to each insert molded typeterminal.

As another alternative, a positive external terminal and a negativeexternal terminal are connected, respectively, to the insert molded typepositive terminal and insert molded type negative terminal. For example,the external terminals are provided with one or more through holes toallow a bolt to connect the respective external terminal to the insertmolded type terminal. The external terminals can be provided with one ormore threaded holes to allow a bolt to connect the externals terminalsto the respective positive battery cable and negative battery cable.

The battery can be structured and arranged to cooperate with one or morebattery trays to change the effective height of the battery. Forexample, the bottom section of the battery casing can be configured tonest within an upper receiver of a battery tray. The battery tray canhave different heights. Further, a lower end of the battery tray can beconfigured to nest within the upper receiver of another battery tray toprovide a stacked arrangement of battery trays. For example, a pluralityof same height or different height battery trays can be stacked totailor a final assembled height of the battery with battery trays for aparticular battery installation on a vehicle.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein theupper section is defined by an outer perimeter wall extending downwardlyfrom an upper wall, wherein the middle section is defined by an outerperimeter wall extending upwardly from a bottom wall, and wherein thelower section is defined by an outer perimeter wall extending upwardlyfrom a bottom wall.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein thepositive battery terminal is spaced apart from the negative batteryterminal, and wherein the positive battery terminal and negative batteryterminal extend through the upper wall of the upper section of thebattery casing.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein thepositive battery terminal is spaced apart from the negative batteryterminal, and wherein the positive battery terminal and negative batteryterminal extend through the upper wall of the upper section of thebattery casing, wherein the positive battery terminal is an insertmolded type positive battery terminal insert molded type into the upperwall of the upper section of the battery casing, and wherein thepositive battery terminal is an insert molded type positive batteryterminal insert molded type into the upper wall of the upper section ofthe battery casing.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, furthercomprising an external removable positive terminal connected to thepositive battery terminal, and an external removable negative terminalconnected to the negative battery terminal.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein theupper section and lower section of the battery casing are heat weldedtogether during assembly of the battery casing.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein themiddle section and lower section of the battery casing are configured tosnap fit together during assembly of the battery casing.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein theupper section is defined by an outer perimeter wall extending downwardlyfrom an upper wall, wherein the middle section is defined by an outerperimeter wall extending upwardly from a bottom wall, and wherein thelower section is defined by an outer perimeter wall extending upwardlyfrom a bottom wall, further comprising a removable cover disposed withinan upper receiver in the upper wall of the upper section of the batterycasing.

The presently described subject matter is directed to a battery casing,comprising or consisting of: a top section; a middle section connectedto the top section; a lower section connected to the middle section; apositive battery terminal connected to the battery casing; and anegative battery terminal connected to the battery casing, wherein theupper section is defined by an outer perimeter wall extending downwardlyfrom an upper wall, wherein the middle section is defined by an outerperimeter wall extending upwardly from a bottom wall, wherein the lowersection is defined by an outer perimeter wall extending upwardly from abottom wall, further comprising a removable cover disposed within anupper receiver in the upper wall of the upper section of the batterycasing, and wherein the removable cover is connected to the upper wallof the upper section of the battery casing by a fastener.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing comprising a topsection, middle section, and lower section connected together; apositive battery terminal connected to the battery casing; a negativebattery terminal connected to the battery casing; a rechargeable batterypack disposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing comprising a topsection, middle section, and lower section connected together; apositive battery terminal connected to the battery casing; a negativebattery terminal connected to the battery casing; a rechargeable batterypack disposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, further comprising a positive cable connecting the rechargeablebattery pack to the circuit board, and a negative cable connecting therechargeable battery pack to the circuit board.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein upper section is defined by anouter perimeter wall extending downwardly from an upper wall, whereinthe middle section is defined by an outer perimeter wall extendingupwardly from a bottom wall, and wherein the lower section is defined byan outer perimeter wall extending upwardly from a bottom wall.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the positive battery terminal is spaced apart from thenegative battery terminal, and wherein the positive battery terminal andnegative battery terminal extend through the upper wall of the uppersection of the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the positive battery terminal is spaced apart from thenegative battery terminal, and wherein the positive battery terminal andnegative battery terminal extend through the upper wall of the uppersection of the battery casing, and wherein the positive battery terminalis an insert molded type positive battery terminal insert molded typeinto the upper wall of the upper section of the battery casing, andwherein the positive battery terminal is an insert molded type positivebattery terminal insert molded type into the upper wall of the uppersection of the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, further comprising an external removable positive terminalconnected to the positive battery terminal, and an external removablenegative terminal connected to the negative battery terminal.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein the upper section and lowersection of the battery casing are heat welded together during assemblyof the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein the middle section and lowersection of the battery are snap fit together during assembly of thebattery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein the circuit board comprisesmultiple spaced apart copper plates.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein the circuit board comprisesmultiple spaced apart copper plates, and wherein the circuit boardcomprises one or more MOSFETs bridging a pair of the spaced apart copperplates.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein the circuit board comprisesmultiple spaced apart copper plates, wherein the circuit board comprisesone or more MOSFETs bridging a pair of the spaced apart copper plates,and wherein the circuit board comprises one or more current senseresistors bridging another pair of spaced apart copper plates.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and wherein each copper platecomprises one or more inclined edges relative to a length dimension ofthe circuit board.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and wherein each copper platecomprises one or more transverse edges relative to a length dimension ofthe circuit board.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and wherein the circuit board isphysically connected to the positive battery terminal and the negativebattery terminal.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and wherein the circuit board isphysically connected to the positive battery terminal and the negativebattery terminal, and wherein the positive battery terminal includes athreaded portion extending into the casing and physically connecting tothe circuit board, and the negative battery terminal includes a threadedportion extending into the casing and physically connecting to thecircuit board.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing, wherein the one ormore trays is configured so that the lower end of the battery casingnests within the one or more trays.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing, wherein the one ormore trays is configured with one or more protrusions to connected withone or more receivers in the lower end of the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing, wherein the one ormore trays is configured so that the lower end of the battery casingnests within the one or more trays, wherein the one or more trays isconfigured with one or more protrusions to connected with one or morereceivers in the lower end of the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, wherein the one or more trays isconnected to a lower section of the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing, wherein the one ormore trays is multiple trays connected together with the battery casing.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing, wherein the one ormore trays is multiple trays connected together with the battery casing,and wherein the multiple trays have a same height.

The presently described subject matter is directed to a rechargeablebattery, comprising or consisting of: a battery casing; a positivebattery terminal connected to the battery casing; a negative batteryterminal connected to the battery casing; a rechargeable battery packdisposed within the battery casing; and a battery management systemcomprising a circuit board, the circuit board electrically connected tothe positive battery terminal and the negative battery terminal, thecircuit board being electrically connected to the rechargeable batterypack, wherein the battery comprise an upper section, middle section, andlower section connected together, and further comprising one or moretrays connected to a lower end of the battery casing, wherein the one ormore trays is multiple trays connected together with the battery casing,and wherein multiple trays have at least two different heights.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery tray isconfigured so that the lower end of the battery nests within the batterytray.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery tray isconfigured so that the lower end of the battery nests within the batterytray, wherein a height of the inner perimeter wall is less than a heightof the outer perimeter wall.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery trayscomprises one or more protrusions configured to connected to one or morereceivers provided in a bottom portion of the battery.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery tray isconfigured so that the lower end of the battery nests within the batterytray, and wherein the battery trays comprises one or more protrusionsconfigured to connected to one or more receivers provided in a bottomportion of the battery.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery tray isconfigured so that the lower end of the battery nests within the batterytray, wherein the battery trays comprises one or more protrusionsconfigured to connected to one or more receivers provided in a bottomportion of the battery, and wherein the battery tray isrectangular-shaped, and the one or more protrusions are four protrusionslocated adjacent to four corners of the battery tray cooperating withfour recessed holes in the bottom portion of the battery.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery tray isbottomless inside the inner perimeter wall.

The presently described subject matter is directed to a battery tray foruse with a battery for extending a height of the battery, the batterytray comprising or consisting of a lower wall with an inner perimeterwall extending upwardly from the lower wall and an outer perimeter wallextending upwardly from the wall, the inner perimeter wall being spacedapart from the outer perimeter wall, the battery tray being configuredto connect to a lower end of the battery, wherein the battery tray isprovided with a bottom wall located inside and connected to the innerperimeter wall.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a battery according to the presentinvention.

FIG. 2 is a front view of the battery shown in FIG. 1 .

FIG. 3 is a rear view of the battery shown in FIG. 1 .

FIG. 4 is a top view of the battery shown in FIG. 1 .

FIG. 5 is a bottom view of the battery shown in FIG. 1 .

FIG. 6 is a left view of the battery shown in FIG. 1 .

FIG. 7 is a right view of the battery shown in FIG. 1 .

FIG. 8 is a perspective view showing the cover separated from thebattery shown in FIG. 1 .

FIG. 9 is perspective view of the cover of the battery shown in FIG. 8 .

FIG. 10 is front view of the cover shown in FIG. 8 .

FIG. 11 is a rear view of the cover shown in FIG. 8 .

FIG. 12 is a top view of the cover shown in FIG. 8 .

FIG. 13 is a bottom view of the cover shown in FIG. 8 .

FIG. 14 is a left side view of the cover shown in FIG. 8 .

FIG. 15 is a right side view of the cover shown in FIG. 8 .

FIG. 16 is a perspective view of battery shown in FIG. 1 fitted withexternal removable terminals.

FIG. 17 is a front view of the battery shown in FIG. 16 .

FIG. 18 is a top view of the battery shown in FIG. 16 .

FIG. 19 is left side view of the battery shown in FIG. 16 .

FIG. 20 is a right side view of the battery shown in FIG. 16 .

FIG. 21 is an exploded perspective view of the battery shown in FIG. 16.

FIG. 22 is an exploded front view of the battery shown in FIG. 16 .

FIG. 23 is an exploded right side view of the battery shown in FIG. 16 .

FIG. 24 is an exploded perspective view of the battery shown in FIG. 1fitted with a pair of different height battery trays.

FIG. 25 is an exploded front view of the battery shown in FIG. 1 fittedwith a pair of different height battery trays.

FIG. 26 is an exploded right side view of the battery shown in FIG. 1fitted with a pair of different height battery trays.

FIG. 27 is a perspective view of the greater height (i.e. thicker)battery tray shown in FIG. 24 .

FIG. 28 is a front view of the greater height (i.e. thicker) batterytray shown in FIG. 24 .

FIG. 29 is a top view of the greater height (i.e. thicker) battery trayshown in FIG. 24 .

FIG. 30 is a bottom view of the greater height (i.e. thicker) batterytray shown in FIG. 24 .

FIG. 31 is a left side view of the greater height (i.e. thicker) batterytray shown in FIG. 24 .

FIG. 32 is a perspective view of a less height (i.e. thinner) batterytray shown in FIG. 39 .

FIG. 33 is a front view of the battery tray shown in FIG. 32 .

FIG. 34 is a top view of the battery tray shown in FIG. 32 .

FIG. 35 is a bottom view of the battery tray shown in FIG. 32 .

FIG. 36 is a left side view of the battery tray shown in FIG. 32 .

FIG. 37 is an exploded perspective view of the battery shown in FIG. 1fitted with the battery tray shown in FIG. 32 .

FIG. 38 is an exploded perspective view of the battery shown in FIG. 1being fitted with external removable terminals via bolts.

FIG. 39 is an exploded perspective view of the battery shown in FIG. 1being fitted with a plurality of battery trays of same and differentheights (i.e. thicknesses).

FIG. 40 is a perspective view of the assembled battery shown in FIG. 39.

FIG. 41 is a perspective view of another battery according to thepresent invention having a greater length and less width compared to thebattery shown in FIG. 1 .

FIG. 42 is perspective view of a further battery according to thepresent invention having less length and greater width compared to thebattery shown in FIG. 1 .

FIG. 43 is a perspective view of an external removable battery terminalaccording to the present invention for use with the battery shown inFIG. 1 .

FIG. 44 is a front view of an external removable battery terminal shownin FIG. 43 .

FIG. 45 is a rear view of an external battery shown in FIG. 43 .

FIG. 46 is a top view of an external battery terminal shown in FIG. 43 .

FIG. 47 is a bottom view of an external battery terminal shown in FIG.43 .

FIG. 48 is a left side view of an external battery terminal shown inFIG. 43 .

FIG. 49 is a right side view of an external battery terminal shown inFIG. 43 .

FIG. 50 is a perspective view of another external battery terminalaccording to the present invention.

FIG. 51 is a front view of an external battery terminal shown in FIG. 50.

FIG. 52 is a rear view of an external battery shown in FIG. 50 .

FIG. 53 is a top view of an external battery terminal shown in FIG. 50 .

FIG. 54 is a bottom view of an external battery terminal shown in FIG.50 .

FIG. 55 is a left side view of an external battery terminal shown inFIG. 50 .

FIG. 56 is a right side view of an external battery terminal shown inFIG. 50 .

FIG. 57 is a perspective view of an insert molded type battery terminalaccording to the present invention.

FIG. 58 is a front view of the insert molded type battery terminal shownin FIG. 57 .

FIG. 59 is a rear view of the insert molded type battery terminal shownin FIG. 57 .

FIG. 60 is a top view of the insert molded type battery terminal shownin FIG. 57 .

FIG. 61 is a bottom view of the insert molded type battery terminalshown in FIG. 57 .

FIG. 62 is a left side view of the insert molded type battery terminalshown in FIG. 57 .

FIG. 63 is a right side view of the insert molded type battery terminalshown in FIG. 57 .

FIG. 64 is an exploded perspective view of the battery shown in FIG. 1showing the components or parts thereof.

FIG. 65 is a planar view of the battery management system (BMS) printedcircuit board according to the present invention and shown in FIG. 64 .

FIG. 66 is a disassembled perspective view of a battery according to thepresent invention similar to the battery shown in FIG. 1 .

FIG. 67 is a planar view of another battery management system (BMS)printed circuit board.

FIG. 68 is a planar view of a further battery management system (BMS)printed circuit board.

FIG. 69 is a planar view of an even further battery management system(BMS) printed circuit board.

FIG. 70 is a planar view of the battery management system (BMS) printedcircuit board shown in FIG. 65 .

FIG. 71 is a perspective view of the middle section and lower section ofthe battery casing of the battery shown in FIG. 1 showing the snap fitconnection between the middle section and lower section of the batterycasing.

FIG. 72 is a front view of the middle section and lower section of thebattery casing of the battery shown in FIG. 1 showing the snap fitconnection between the middle section and lower section of the batterycasing.

FIG. 73 is a front view of the middle section assembled to the lowersection of the battery casing of the battery shown in FIG. 1 showing thesnap fit connection between the middle section and lower section of thebattery casing.

FIG. 74 is a lengthwise vertical cross-sectional view of the shown inFIG. 1 fitted with a battery tray showing the protraction of the batterytray fitting into the recessed holes in the bottom of the battery casingof the battery.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

A rechargeable battery 10 according to the present invention is shown inFIG. 1-7 . For example, the rechargeable battery 10 is a rechargeablelithium ion battery.

The rechargeable battery 10 comprises a battery casing 12, insert moldedtype positive battery terminal 14, insert molded type negative batteryterminal 16, and a cover 18.

The battery casing 12 comprises an upper section 12A, middle section12B, and lower section 12C. The insert molded type positive batteryterminal 14 and the insert molded type negative battery terminal 16 arespaced apart, and insert molded type into an upper wall 12AA of theupper battery section 12A. The positive battery terminal 14 is providedwith a threaded hole 14A and the negative battery terminal 16 isprovided with a threaded hole 16B. The threaded holes 14A, 14Baccommodate bolt fastener for releasably connecting a positive batterycable and a negative battery cable, respectively, to the positivebattery terminal 14 and negative battery terminal 16.

The upper surface of the upper section 12A is provided with an X-shapedprotrusion 12AB, a molded positive symbol 12AC, and a molded negativesymbol 12AD as shown.

A cover 18 having a bolt head receiver 18A and through hole 18B (FIGS.9-12 ) is removably connected to the upper section 12A of the batterycasing 12. The cover 18 is removably connected to the upper section 12Aof the battery casing via a bolt 20 having a bolt head 20A (FIG. 8 )connecting with an insert molded type anchor 22 having a threaded hole22A, as shown in FIG. 8 . The cover 18 fits into a receiver 12AE of theupper section 12A of the battery casing 12. The structure andarrangement of the cover 18 is shown in FIGS. 9-12 .

The battery casing 12 includes a vertical channel 12D and a curvedhorizontal rib 12E on the front side (FIG. 2 ) thereof, and a verticalchannel 12F and a curved horizontal rib 12F on the rear side (FIG. 3 )thereof.

The bottom of the lower section 12C (FIG. 5 ) of the battery casing 12is provided with four (4) holes 12H located at the corners thereof.

The insert molded type positive terminal 14 and insert molded typenegative terminal 16 of the rechargeable battery 10 can be directlyconnected to battery cables, for example, of a vehicle. Specifically,the ends of the battery cables can be fitted with connector ends havingthrough holes to allow bolts to connect the connector ends,respectively, directly to the insert molded type terminals 14, 16.Alternatively, the insert molded type positive terminal 14 and insertmolded type negative terminal 16 of the rechargeable battery 10 can befitted with a positive terminal 24 and a negative terminal 26.Specifically, fastening bolts 24A, 26A can connect, respectively, theterminals 24, 26 to the insert molded type terminals 14, 16. Thefastening bolts 24A, 26A, for example, can have Phillips-head type boltheads 24B, 26B (FIG. 18 ).

The positive terminal 24 is provided with threaded holes 24C located,for example, on one side or multiple sides (e.g. three sides shown inFIG. 21 ) of the positive terminal 24. The negative terminal 26 isprovided with threaded holes 26C located, for example, on one side ormultiple sides (e.g. three sides shown in FIG. 21 ) of the negativeterminal 26. The positive terminal 24 and the negative terminal 26 ofthe rechargeable battery 10 can be directly connected to battery cables,for example, of a vehicle. Specifically, the ends of the battery cablescan be fitted with connector ends having through holes to allow bolts toconnect the connector ends, respectively, directly to the terminals 24,26.

The detailed structure and arrangement of the battery casing 12 is shownin FIGS. 21 and 22 . The upper section 12A, middle section 12B, andlower section 12C of the battery casing are separate parts (e.g. plasticinjection molded parts), for example, that can be heat welded, adhered,and/or snap fit together for assembly of the battery casing 12. Forexample, the middle section 12B is provided with a plurality of snap fitindents 12BA for cooperating with a plurality of snap fit protrusions(not shown) located on the inside perimeter of the lower section 12C ofthe battery casing 12.

The detailed structure and arrangement of the cover 18 configured forcooperating with the receiver 12AE of the upper section 12A of thebattery casing is shown in FIGS. 9-15 . For example, the cover 18 is aplastic injection molded part. The bottom (FIG. 13 ) of the cover 18,for example, can be configured with multiple cells 18C defined bymultiple ribs 18D to provide added structural strength and light weightfeatures. For example, the multiple ribs 18D are transverse rib relativeto a length dimension of the cover 18 resulted in transverse elongatedcells. In addition, a reinforcing collar of increased thickness isprovided surrounding the through hole 18B to strengthen the holestructure and prevent tearing thereof. The cover 18 assembled onto theupper section 12A of the battery casing 12 is shown in FIG. 16 .

Trays

The rechargeable battery 10 can be provided or fitted with one or moretrays, as shown in FIGS. 24 and 25 . For example, multiple trays can beprovided or fitted to the rechargeable battery 10 to provide a “stacked”arrangement for adjusting or tailoring the physical height of therechargeable battery 10. For example, the rechargeable battery 10 isprovided or fitted with a tray 30 and a tray 32, as shown in FIGS. 24and 25 . The tray 32 is thicker in height dimension relative to the tray30, as shown in FIG. 24 .

The tray 30, for example, is configured to connect to the lower section12C of the battery casing 12. For example, the lower section 12C of thebattery casing 12 is configured to nest within the upper side of thetray 30. Alternatively, or in addition, the lower section 12C and/or thetray 30 can be provided with connectors to permanently connect (e.g.using interference fit connectors, snap fit connectors, welded oradhered together connectors) or removably connect (e.g. usingmale/female type connectors) the lower section 12C and the tray 30together. For example, the connectors can be protrusions 30A located onthe upper side of the tray 30 cooperating with receivers (e.g. holes 12Hshown in FIG. 5 ) located on the lower side of the lower section 12C ofthe battery casing 12. Alternatively, the protrusions 30A can be pins(e.g. plastic, plastic composite, metal pins, metal alloy pins).

The tray 32, for example, is configured to connect to the lower side ofthe tray 30. For example, the lower side of the tray 30 is configured tonest within the upper side of the tray 32. Alternatively, or inaddition, the tray 30 and/or the tray 32 can be provided with connectorsto permanently connect (e.g. using interference fit connectors, snap fitconnectors, welded or adhered together connectors) or removably connect(e.g. using male/female type connectors) the tray 30 and tray 32together. For example, the connectors can be protrusions 32A located onthe upper side of the tray 32 cooperating with receivers (e.g. holes30D) located on the lower side of the tray 30. Alternatively, theprotrusions 32A can be pins (e.g. plastic or metal pins).

The details of the tray 32 is shown in FIGS. 27-31 . The upper side ofthe tray 32 is provided with four (4) protrusions 32A located in thecorners of the tray 32. The protrusions, for example, can have oppositerounds side and opposite flat sides, as shown in FIG. 30 . The trays 32includes an inner edge 32B defining an opening 32C and a spaced apartsurrounding outer edge 32E, as shown in FIG. 27 . Alternatively, theopening 32C can be closed by providing wall inside the inner edge 32B.

The height of the inner edge 32B is less than the height of the outeredge 32D so that the lower side of the tray 30 nests within the outeredge 32 of the tray 32, as shown in FIGS. 24-26 . Specifically, areceiver 32E for accommodating and nesting with the lower side of thetray 30 is defined by the inner side 32DA of the outer edge 32 and anupper edge 32BA of the inner edge 32B of the tray 32. The upper edge32BA serves as a stop for ingress of the lower side of the tray 30 intothe receiver 32E. After assembly of the tray 30 and tray 32 together,the lower side surface of the tray rests in contact with the upper edge32BA of the inner edge 32B of the tray 32.

The tray 32 is provided with a channel 32D that is continuous with thechannel 12D of the battery casing 12, as shown in FIG. 24 .

The lower side of the tray 32 is provided with recessed holes 32E (FIG.29 ) for accommodating protrusions of another tray that can be providedor fitted to a lower side of the tray 32 to provide a further “stacked”arrangement of trays. The inner surface of the tray 32 is provided witha cell-shaped ridges 32 structurally reinforcing the lower wall of thetray 32.

Another tray 34 is shown in FIGS. 32-36 . The tray 34 is a lower profiletray having less height compared to tray 30. The tray 34 can be providedor fitted onto the bottom of rechargeable battery 10, as shown in FIG.37 .

The rechargeable battery 10 can be provided or fitted with a single trayor a stack of trays. The trays can have the same height, or can bedifferent heights. For example, the rechargeable battery 10 shown inFIG. 39 is provided or fitted with a stack of trays, including three (3)trays 32, one (1) tray 30, and one (1) tray 34 from the top of the stackto the bottom of the stack. In this manner, the overall height of therechargeable battery 10 with trays can be varied, adjustable, orotherwise tailored to a particular height application.

The length, width, and the height of the rechargeable battery accordingto the present invention can vary depending on the particularapplication. For example, the rechargeable battery 10′ shown in FIG. 41has a greater length and less width compared to the rechargeable battery10 shown in FIG. 1 . The rechargeable battery 10″ shown in FIG. 42 has ashorter length and a greater width compared to the rechargeable battery10 shown in FIG. 1 .

A detailed view of the terminal 26 (FIGS. 21 and 22 ) is shown in FIGS.43-49 . The terminal 24 is a mirror image of the terminal 26.

The terminal 26, for example, comprises a rectangular-shaped base 27Ahaving a raised circular-shaped surround 27B accommodating the throughhole 24F. An L-shaped flange 27C extends upwardly from therectangular-shaped base 27A. The two (2) sides of the flange 27C areeach provided with the threaded through holes 26C to accommodate a bolt,for example, for connecting a battery cable to the terminal 26 at two(2) different locations depending on the particular application. The topof the flange 27C is provided with a threaded hole 26C to accommodatebolt 26A (FIG. 38 ) for connecting the terminal 26 to the insert moldedtype terminal 16 of the rechargeable battery 10. The terminal 26 isprovided with raised round-shaped surrounds 27D accommodating thethreaded holes 26C. The flange 27C is provided with ribs 27CA definingrecesses 27CB to structurally strengthen the flange 27C structure andarrangement. The bottom of the flange 26 is provided with an L-shapedrecess 27E, as shown in FIG. 47 .

The terminal 26 can be a molded metal part, or machined from a billet orblock of conductive metal (e.g. lead, copper, aluminum, bronze). Theraised circular-shaped portions 27B, 27D can be machined flat (e.g.milled) after molding the part to finish the surrounds to the throughholes 26C, 26F.

Another design of the terminal 26′ is shown in FIGS. 50-56 . In thisdesign, the flange 27C′ is provided with only a single threaded hole26C′, and the surround 27D′ on top of the flange 27C′ is modified due toan enlarge surround 27B.

A detailed view of the insert molded type terminal 16 (FIGS. 57-63 ) isshown in FIGS. 43-49 . The insert molded type terminal 14 is a mirrorimage of the insert molded type terminal 16.

The insert molded type terminal 16 includes a rectangular-shaped plate16B having the threaded hole 16A located on top of a cylindrical-shapedbody 16C having a pair of spaced apart ring-shaped portions 16D. Theouter surface of the ring shaped portion 16D is knurled to enhancegripping when insert molded type into the wall of the upper section 12Aof the battery casing 12. A threaded body 16E extends downwardly fromthe cylindrical-shaped body 16C.

Rechargeable Battery Assembly

The structure and arrangement of the assembled rechargeable battery 10(i.e. rechargeable battery assembly) is shown in FIG. 64 .

The battery casing 12 includes the upper section 12A, middle section12B, and lower section 12C. The cover 18 removably connects to the uppersection 12A via the bolt 20.

A rechargeable battery pack 50 is disposed or installed within thebattery casing 12. For example, bottom foam block 52 and side foamblocks 54, 56 are installed around the rechargeable battery pack 50 tocenter and protect the installed rechargeable battery pack 50 within thebattery casing 12.

A circuit board 58 is then installed above the rechargeable battery pack50. A positive ring terminal 60 is connected a positive terminal of thecircuit board 58 via the threaded end of the insert molded type positiveterminal 14. The positive ring terminal 60 is connected to the positiveterminal of the rechargeable battery pack 50 via a positive batterycable (not shown). A negative ring terminal 62 is connected to anegative terminal of the circuit board 58 via a bolt 64. The negativering terminal 62 is connected to the negative terminal of therechargeable battery pack 50 via a negative battery cable (not shown).The threaded end of the insert molded type negative terminal 16 isconnected to another negative terminal of circuit board 58. The nuts 66are used to connect the threaded ends of the insert molded typeterminals 14, 16 and the ring terminals 60, 62 to the circuit board 58.

A pair of terminal covers 68 are removably connected to the terminals24, 26. Further, four (4) foam blocks 70 can be placed inside center ofthe trays for packaging.

Battery Management System (BMS) with Circuit Board

The rechargeable battery 10 includes a battery management system (BMS)circuit board 58, as shown in FIGS. 64 and 65 . The circuit board 58shown in FIG. 65 , for example, is oriented upside down when beinginstalled within the battery casing 12, as shown in FIG. 64 .

The circuit board 58 includes spaced apart conductive (e.g. copper)plates 70A, 70B, 70C, 70D each having one or more inclined edgesrelative to the length of the circuit board 58. Three (3) MOSFETs 72 areinstalled between (i.e. bridge) conductive plates 70A and 70B andanother three (3) MOSFETs 72 are installed between conductive plates 70Band 70C, as shown in FIG. 65 . Two (2) current sense resistors 74 areinstalled between (i.e. bridging) conductive plates 70C and 70D. Thecircuit board 58 also includes a 2 pin connector 76 and a 5 pinconnector 78 for connection to the rechargeable battery pack 50.

A positive battery cable 82 connects between the positive terminal ofthe rechargeable battery pack 50 and the positive ring terminal 60. Thepositive ring terminal 60 is connected to the threaded end of the insertmolded type positive terminal 14 and the circuit board 58 via nut 66.

A negative battery cable 84 connects between the negative terminal ofthe rechargeable battery pack 50 and the negative ring terminal 62. Thenegative ring terminal 62 is connected to the conductive plate 70D ofthe circuit board 58 via bolt 64 and nut 66.

The threaded end of the insert molded type negative terminal 16 connectsto the conductive plate 70A of the circuit board 58 via the nut 66.

The circuit board (e.g. circuit board 58) can have various otherconfigurations or layouts. Specifically, the shape of the conductiveplates, the location and arrangement of the conductive plates on theboard, the locations and arrangement of the connections with therechargeable battery, the locations and arrangement of the insert moldedtype terminals 14, 16, on the board, and other features can vary frommodel to model, as shown in FIGS. 69-70 . The circuit boards can havespaced apart conductive plates with one or more inclined edges inclinedrelative to a length of the circuit board and/or spaced apart conductiveplates with one or more transverse edges set transverse relative to thelength of the circuit board.

Snap Fit Battery Casing

A snap fit battery casing 12 is shown in FIGS. 71-74 . The middlesection 12B is provided with snap fit recesses 12BA configured to snapfit with protrusions 12CA on the inside rim of the lower section 12B.This arrangement allows the middle section 12B and lower section 12C tosnap fit together during assembly of the casing. The same arrangementcan be provided between the upper section 12A and 12B.

The lower section 12C can be provided or fitted with a tray (e.g. tray34 as shown). The tray 34 is provided with four (4) protrusions 34Aconfigured to be received within recessed holes 12H located on thebottom of the lower section 12C of the battery casing 12.

DRAWING SCHEDULE

-   -   10 rechargeable battery    -   12 battery casing    -   12A upper section    -   12AA upper wall    -   12AB X-shaped protrusion    -   12AC molded positive symbol    -   12AD molded negative symbol    -   12AE receiver    -   12B middle section    -   12C lower section    -   12D vertical channel    -   12E curved horizontal rib    -   12F vertical channel    -   12G curved horizontal rib    -   14 insert molded type positive battery terminal    -   14A threaded hole    -   16 insert molded type negative battery terminal    -   16A threaded hole    -   18 cover    -   18A bolt head receiver    -   18B through hole    -   18C cell    -   18D rib    -   20 bolt    -   20A bolt head    -   22 insert molded type anchor    -   22A threaded hole    -   24 positive terminal    -   24A bolt    -   24B bolt head    -   24C threaded hole    -   24D bolt    -   24E bolt head    -   24F through hole    -   26 negative terminal    -   26A bolt    -   26B bolt head    -   26C threaded hole    -   26D bolt    -   26E bolt head    -   26F through hole    -   27A rectangular-shaped base    -   27B raised circular-shaped surround    -   27C L-shaped flange    -   27D raised circular-shaped surround    -   27E L-shaped recess    -   30 tray    -   30A protrusion    -   32 tray    -   32A protrusion    -   34 tray    -   34A protrusion    -   50 rechargeable battery pack    -   52 bottom foam block    -   54 side foam block    -   56 side foam block    -   58 circuit board    -   60 positive ring terminal    -   62 negative ring terminal    -   64 bolt    -   66 nut    -   68 terminal cover    -   70 foam block    -   70A conductive plate    -   70B conductive plate    -   70C conductive plate    -   70D conductive plate    -   72 MOSFET    -   74 current sense resistor    -   76 2 pin connector    -   78 5 pin connector

The invention claimed is:
 1. A battery casing, comprising: an uppersection; a middle section connected to the top section; a lower sectionconnected to the middle section; a positive battery terminal connectedto the battery casing; a negative battery terminal connected to thebattery casing; an external positive terminal removably attached to thepositive battery terminal, the external positive terminal including afirst positive through hole having a first orientation and a secondpositive through hole having a second orientation different from thefirst orientation, the external positive terminal configured to receivea positive battery cable at the first positive through hole or thesecond positive through hole; and an external negative terminalremovably attached to the negative battery terminal, the externalnegative terminal including a first negative through hole having a thirdorientation and a second negative through hole having a fourthorientation different from the third orientation, the external negativeterminal configured to receive a negative battery cable at the firstnegative through hole or the second negative through hole.
 2. Thebattery casing according to claim 1, wherein the upper section isdefined by a first outer perimeter wall extending downwardly from anupper wall, wherein the middle section is defined by a second outerperimeter wall extending upwardly from a first bottom wall, and whereinthe lower section is defined by a third outer perimeter wall extendingupwardly from a second bottom wall.
 3. The battery casing according toclaim 2, further comprising a removable cover disposed within an upperreceiver in the upper wall of the upper section of the battery casing.4. The battery casing according to claim 3, wherein the removable coveris connected to the upper wall of the upper section of the batterycasing by a fastener.
 5. The battery casing according to claim 1,wherein the positive battery terminal is spaced apart from the negativebattery terminal, and wherein the positive battery terminal and negativebattery terminal extend through an upper wall of the upper section ofthe battery casing.
 6. The battery casing according to claim 5, whereinthe positive battery terminal is an insert molded type positive batteryterminal insert molded type into the upper wall of the upper section ofthe battery casing, and wherein the negative battery terminal is aninsert molded type negative battery terminal insert molded type into theupper wall of the upper section of the battery casing.
 7. The batterycasing according to claim 1, wherein the upper section and the lowersection of the battery casing are adhered together during assembly ofthe battery casing.
 8. The battery casing according to claim 1, whereinthe middle section and the lower section of the battery casing areconfigured to snap fit together during assembly of the battery casing.9. The rechargeable battery of claim 1, wherein: the external positiveterminal further comprises a third positive through hole having a fifthorientation different from the first orientation and the secondorientation, the external positive terminal further configured toreceive the positive battery cable at the third positive through hole;and the external negative terminal further comprises a third negativethrough hole having a sixth orientation different from the thirdorientation and the fourth orientation, the external negative terminalfurther configured to receive the negative battery cable at the thirdnegative through hole.
 10. The rechargeable battery of claim 9, furthercomprising a first bolt configured to removably attach the externalpositive terminal to the positive battery terminal and a second boltconfigured to removably attach the external negative terminal to thenegative battery terminal.
 11. A rechargeable battery, comprising: abattery casing comprising an upper section, middle section, and lowersection connected together, the upper section including a top surfaceand an indented receiver portion; a positive battery terminal connectedto the battery casing; a negative battery terminal connected to thebattery casing; a rechargeable battery pack disposed within the batterycasing; and a cover configured to removably attach to the indentedreceiver portion of the upper section, the cover having a top surfacethat is substantially flush with the top surface of the upper sectionwhen the cover is attached to the indented receiver portion.
 12. Therechargeable battery according to claim 11, further comprising a circuitboard, a positive cable connecting the rechargeable battery pack to thecircuit board, and a negative cable connecting the rechargeable batterypack to the circuit board.
 13. The rechargeable battery according toclaim 12, wherein the middle section and the lower section of thebattery casing snap fit together during assembly of the battery casing.14. The rechargeable battery according to claim 12, wherein the circuitboard is physically connected to the positive battery terminal and thenegative battery terminal.
 15. The rechargeable battery according toclaim 14, wherein the positive battery terminal includes a threadedportion extending into the battery casing and physically connecting tothe circuit board, and the negative battery terminal includes a threadedportion extending into the battery casing and physically connecting tothe circuit board.
 16. The rechargeable battery according to claim 11,wherein the upper section is defined by a first outer perimeter wallextending downwardly from an upper wall, wherein the middle section isdefined by a second outer perimeter wall extending upwardly from a firstbottom wall, and wherein the lower section is defined by a third outerperimeter wall extending upwardly from a second bottom wall.
 17. Therechargeable battery according to claim 11, wherein the positive batteryterminal is spaced apart from the negative battery terminal, and whereinthe positive battery terminal and negative battery terminal extendthrough an upper wall of the upper section of the battery casing. 18.The rechargeable battery according to claim 17, wherein the positivebattery terminal is an insert molded type positive battery terminalinsert molded type into the upper wall of the upper section of thebattery casing, and wherein the negative battery terminal is an insertmolded type negative battery terminal insert molded type into the upperwall of the upper section of the battery casing.
 19. The rechargeablebattery according to claim 11, further comprising an external removablepositive terminal connected to the positive battery terminal, and anexternal removable negative terminal connected to the negative batteryterminal.
 20. The rechargeable battery according to claim 11, whereinthe upper section and the lower section of the battery casing areadhered together during assembly of the battery casing.
 21. Therechargeable battery according to claim 11, wherein the circuit boardcomprises multiple spaced apart copper plates.
 22. The rechargeablebattery according to claim 21, wherein the circuit board comprises oneor more MOSFETs bridging a pair of the spaced apart copper plates. 23.The rechargeable battery according to claim 22, wherein the circuitboard comprises one or more current sense resistors bridging a pair ofsecond spaced apart copper plates.
 24. The rechargeable batteryaccording to claim 21, wherein each copper plate comprises one or moreinclined edges relative to a length dimension of the circuit board. 25.The rechargeable battery according to claim 21, wherein each copperplate comprises one or more transverse edges relative to a lengthdimension of the circuit board.
 26. The rechargeable battery accordingto claim 11, further comprising one or more trays connected to a lowerend of the battery casing.
 27. The rechargeable battery according toclaim 26, wherein the one or more trays is configured so that the lowerend of the battery casing nests within the one or more trays.
 28. Therechargeable battery according to claim 27, wherein the one or moretrays is configured with one or more protrusions to connect with one ormore receivers in the lower end of the battery casing.
 29. Therechargeable battery according to claim 26, wherein the one or moretrays is configured with one or more protrusions to connect with one ormore receivers in the lower end of the battery casing.
 30. Therechargeable battery according to claim 26, wherein the one or moretrays is connected to the lower section of the battery casing.
 31. Therechargeable battery according to claim 26, wherein the one or moretrays is multiple trays connected together with the battery casing. 32.The rechargeable battery according to claim 31, wherein the multipletrays have a same height.
 33. The rechargeable battery according toclaim 31, wherein the multiple trays have at least two differentheights.
 34. The rechargeable battery according to claim 11, furthercomprising a battery tray for extending a height of the rechargeablebattery, the battery tray comprising a lower wall with an innerperimeter wall extending upwardly from the lower wall and an outerperimeter wall extending upwardly from the lower wall, the innerperimeter wall being spaced apart from the outer perimeter wall, thebattery tray being configured to connect to the lower section of therechargeable battery.
 35. The rechargeable battery according to claim34, wherein the battery tray is configured so that the lower section ofthe rechargeable battery nests within the battery tray.
 36. Therechargeable battery according to claim 35, wherein a height of theinner perimeter wall is less than a height of the outer perimeter wall.37. The rechargeable battery according to claim 35, wherein the batterytray comprises one or more protrusions configured to connect to one ormore receivers provided in a bottom portion of the rechargeable battery.38. The rechargeable battery according to claim 37, wherein the batterytray is rectangular-shaped, and the one or more protrusions are fourprotrusions located adjacent to four corners of the battery traycooperating with four recessed holes in the bottom portion of therechargeable battery.
 39. The rechargeable battery according to claim34, wherein the battery tray comprises one or more protrusionsconfigured to connect to one or more receivers provided in a bottomportion of the rechargeable battery.
 40. The rechargeable batteryaccording to claim 34, wherein the battery tray is bottomless inside theinner perimeter wall.
 41. The rechargeable battery according to claim34, wherein the battery tray is provided with a bottom wall locatedinside and connected to the inner perimeter wall.
 42. The rechargeablebattery according to claim 11, wherein the cover includes a bolt headreceiver and the indented receiver portion of the upper section includesan anchor having a threaded hole, wherein a bolt is used to secure thecover to the indented receiver portion at the bolt head receiver and theanchor.
 43. The rechargeable battery according to claim 11, furthercomprising a battery management system comprising a circuit board, thecircuit board electrically connected to the positive battery terminaland the negative battery terminal, the circuit board being electricallyconnected to the rechargeable battery pack.